2003 CHEVROLET EXPRESS CARGO VAN maintenance

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-34
Air Bag System
.......................................1-63
Restraint System Check
............................1-74
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-19
Starting and Operating Your Vehicle
...........2-20
Mirrors
....................................................2-31
OnStar
žSystem
......................................2-35
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages and Indicators
.........3-23
Audio System(s)
.......................................3-40
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
................. 5-9
All-Wheel Drive
........................................5-46
Rear Axle
...............................................5-47
Front Axle
...............................................5-48
Noise Control System
...............................5-49
Bulb Replacement
....................................5-50
Windshield Wiper Blade Replacement
.........5-55
Tires
......................................................5-56
Appearance Care
.....................................5-80
Vehicle Identi®cation
.................................5-90
Electrical System
......................................5-91
Capacities and Speci®cations
.....................5-97
Normal Maintenance
Replacement Parts
..............................5-100
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information.................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects
............................ 7-8
Index................................................................ 1
2003 Chevrolet Express Owner ManualM

Servicing Your Air Bag-Equipped
Vehicle
Air bags affect how your vehicle should be serviced.
There are parts of the air bag system in several places
around your vehicle. You don't want the system to
in¯ate while someone is working on your vehicle. Your
dealer and the service manual have information
about servicing your vehicle and the air bag system. To
purchase a service manual, see
Service Publications
Ordering Information on page 7-9.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still in¯ate during improper
service. You can be injured if you are close to
an air bag when it in¯ates. Avoid wires
wrapped with yellow tape or yellow
connectors. They are probably part of the air
bag system. Be sure to follow proper service
procedures, and make sure the person
performing work for you is quali®ed to do so.
The air bag system does not need regular maintenance.
1-73

Adding Equipment to Your Air
Bag-Equipped Vehicle
Q:If I add a push bumper or a bicycle rack to the
front of my vehicle, will it keep the air bags
from working properly?
A:As long as the push bumper or bicycle rack is
attached to your vehicle so that the vehicle's
basic structure isn't changed, it's not likely to keep
the air bags from working properly in a crash.
Q:Is there anything I might add to the front of the
vehicle that could keep the air bags from
working properly?
A:Yes. If you add things that change your vehicle's
frame, bumper system, front end sheet metal or
height, they may keep the air bag system
from working properly. Also, the air bag system
may not work properly if you relocate any of the air
bag sensors. If you have any questions about
this, you should contact Customer Assistance
before you modify your vehicle. The phone
numbers and addresses for Customer Assistance
are in Step Two of the
Customer Satisfaction
Procedure on page 7-2
.
Restraint System Check
Checking Your Restraint Systems
Now and then, make sure the safety belt reminder light
and all your belts, buckles, latch plates, retractors
and anchorages are working properly. Look for any other
loose or damaged safety belt system parts. If you see
anything that might keep a safety belt system from doing
its job, have it repaired.
Torn or frayed safety belts may not protect you in a
crash. They can rip apart under impact forces. If a belt
is torn or frayed, get a new one right away.
Also look for any opened or broken air bag covers, and
have them repaired or replaced. (The air bag system
does not need regular maintenance.)
1-74

Notice:If you keep driving your vehicle with this
light on, after a while, your emission controls
may not work as well, your fuel economy may not
be as good and your engine may not run as
smoothly. This could lead to costly repairs that may
not be covered by your warranty.
Notice:Modi®cations made to the engine,
transmission, exhaust, intake or fuel system of your
vehicle or the replacement of the original tires
with other than those of the same Tire Performance
Criteria (TPC) can affect your vehicle's emission
controls and may cause this light to come on.
Modi®cations to these systems could lead to costly
repairs not covered by your warranty. This may
also result in a failure to pass a required Emission
Inspection/Maintenance test.
This light should come on, as a check to show you it is
working, when the ignition is on and the engine is
not running. If the light doesn't come on, have it
repaired. This light will also come on during a
malfunction in one of two ways:
·Light FlashingÐ A mis®re condition has been
detected. A mis®re increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
·Light On SteadyÐ An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
·Reducing vehicle speed.
·Avoiding hard accelerations.
·Avoiding steep uphill grades.
·If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible.
If the light stops ¯ashing and remains on steady, see ªIf
the Light Is On Steadyº following.
If the light continues to ¯ash, when it is safe to do so,
stop the vehicle.Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see ªIf
the Light Is On Steadyº following. If the light is still
¯ashing, follow the previous steps, and see your dealer
for service as soon as possible.
3-34

If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. See
Filling Your Tank on page 5-7. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel. See
Gasoline Octane on page 5-4. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, mis®ring, hesitation
on acceleration or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to ®x any
mechanical or electrical problems that may have
developed.
Emissions Inspection and Maintenance
Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this
inspection could prevent you from getting a vehicle
registration.
Here are some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection if the Check
Engine light is on or not working properly.
Your vehicle will not pass this inspection if the OBD
(on-board diagnostic) system determines that critical
emission control systems have not been completely
diagnosed by the system. The vehicle would be
considered not ready for inspection.
3-35

Add-On Equipment
When you carry removable items, you may need to put
a limit on how many people you carry inside your
vehicle. Be sure to weigh your vehicle before you buy
and install the new equipment.
Towing a Trailer
{CAUTION:
If you don't use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well -- or even
at all. You and your passengers could be
seriously injured. Pull a trailer only if you have
followed all the steps in this section. Ask your
dealer for advice and information about towing
a trailer with your vehicle.
Notice:Pulling a trailer improperly can damage
your vehicle and result in costly repairs not covered
by your warranty. To pull a trailer correctly, follow
the advice in this part, and see your dealer for
important information about towing a trailer with
your vehicle. Additional rear axle maintenance
is required for a vehicle used to tow a trailer. See
ªScheduled Maintenance Servicesº in the Index.
To identify the trailering capacity of your vehicle,
you should read the information in ªWeight of the Trailerº
that appears later in this section.
If yours was built with trailering options, as many are,
it's ready for heavier trailers. But trailering is different
than just driving your vehicle by itself. Trailering means
changes in handling, durability and fuel economy.
Successful, safe trailering takes correct equipment, and
it has to be used properly.
That's the reason for this part. In it are many time-tested,
important trailering tips and safety rules. Many of
these are important for your safety and that of your
passengers. So please read this section carefully before
you pull a trailer.
4-31

Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here's
how to do it:
1. Apply your regular brakes, but don't shift into
PARK (P) yet. Then turn your wheels into the curb
if facing downhill or into traffic if facing uphill.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake and then shift to PARK (P).
5. Release the regular brakes.
When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
·start your engine,
·shift into a gear, and
·release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you're
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission ¯uid (don't over®ll),
engine oil, axle lubricant, belt, cooling system and
brake system. Each of these is covered in this manual,
and the Index will help you ®nd them quickly. If
you're trailering, it's a good idea to review these sections
before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
4-43

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Your Vehicle and the Environment....................6-2
Maintenance Requirements..............................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Scheduled Maintenance...................................6-5
Part B: Owner Checks and Services................6-11
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000km)........................6-11
At Each Fuel Fill..........................................6-11
At Least Once a Month.................................6-11
At Least Twice a Year...................................6-12At Least Once a Year...................................6-13
Part C: Periodic MaintenanceInspections.........6-16
Steering and Suspension Inspection................6-16
Exhaust System Inspection............................6-16
Fuel System Inspection..................................6-16
Engine Cooling System Inspection...................6-16
Throttle System Inspection.............................6-17
Rear Axle Service.........................................6-17
Transfer Case and Front Axle
(All-Wheel Drive) Inspection........................6-17
Brake System Inspection................................6-17
Part D: Recommended Fluids and
Lubricants................................................6-18
Part E: Maintenance Record...........................6-20
Section 6 Maintenance Schedule
6-1